A22.SOW_REFERENCE_6_Rice_Lake_Evaluation_Report_Phase_I_-_Revised_6.15.2016.pdf

FLOW-TECHNICS, INC.

Evaluation Report

For

U.S. Army Corps of Engineers

Rice Lake Habitat

Banner, IL

Submitted by:

FLOW – TECHNICS, INC.

Frankfort, IL.

PHONE: 815-277-2600

FAX: 815-534-5311

Revised 6/15/2016

Equipment

Introduction

Three VUPX 1001 Submersible Pumps were delivered on Monday, May 9, 2016 to

Flow-Technics, Inc. motor shop, Joliet Equipment. The disassembly and evaluation of all three pumps were completed on the following dates.

Pump #1, serial number 58884, disassembled Thursday, May 12, 2016

Pump #2, serial number 58885, disassembled Friday, May 13, 2016

Pump #3, serial number 58886, disassembled Monday, May 16, 2016

Evaluation

We were able to turn the propeller freely. The suction bell was then removed. The propeller cap and locking bolts were removed from the propeller nut.

The unit was laid on its side. We removed the propeller nut and loosened bolts for the wear ring.

The unit was stood back up and we removed the bolts for the wear ring. The unit was lifted up to remove the propeller and wear ring. The stator bolts were then removed and the stator was pulled off. The stator was full of water.

We pulled the rotor assembly out of the discharge diffuser and drained the seal oil. The seal oil was clean.

We removed the upper seal and the bolts for the bearing cover. The rotor was lifted out of the bearing housing which was full of water. The rotor was laid on a skid to remove the bearings and bake the rotor.

We then removed the junction box cover and removed the cable entries.

The upper connection chamber was then removed.

We removed the upper bearing cover and bearing and then the upper bearing housing.

All three units were found in the same condition.

The rotors and stators were cleaned and baked on May 18, 2016 and May 19, 2016. All items tested good and do not need rewinding (See attached reports).

The Stainless Steel Cable Tension Systems were delivered to Flow-Technics, Inc. on

May 26, 2016 for all three (3) pumps and were evaluated.

Conclusion

Based on the evaluation of the pumps it is concluded that all three pumps require all new cables, cable entries, cable seals, bearings, mechanical seals, terminal boards, and corresponding hardware to repair the pumps (See attached chart for VUPX 1001 Spare

Parts List). Additional cable sockets, (part numbers 12180120, 12180087, and

12180065) were ordered from the manufacturer at no additional cost to the customer.

Also recommended is new Shrinking Hose to protect the new cables, as the original shrinking hose cannot be reused. Once shrink hose is shrunk around the cable to prevent the cable from moving around in turbulent water, it cannot be unshrunk to reuse on new cable. It is recommended that each stator winding be dipped in varnish and baked as the existing varnish is light and the magnet wire does move at no additional cost to the customer. Upon evaluation of the steel cables, it is recommended that the Kellem Grips be replaced. The Kellem Grips that were delivered on the pallet were smashed underneath the heavy chain and some of the Kellem Grips were splintered. The original

Kellem Grips were a split mesh and to reuse it would require the lacing to be cut and new lacing to be purchased to lace the Kellem Grips. Lacing the stretched mesh will not be even and will not create a tight grip on the cable. The recommended Kellem Grips are closed mesh. The total additional cost for the recommended parts is $2,792.40 (see chart for part listing) Phase I is completed and it is recommended that Phase II be started.

Additional Parts Recommended:

Part Number Description Qty. Unit Price Ext. Price

12116004 Shrinking Hose 3 – 20 foot sections 60 ft. $19.90 $1,194.00

13036017 Kellem Grip, 2.00-2.49 6 $227.70 $1,366.20

13036016 Kellem Grip, .63-.74 3 $77.40 $232.20

TOTAL: $2,792.40

Pos. No. Part number Description Reuse/Replace Notes

1 31300634 Junction Box Reuse

2 11210163 Cylinder Screw Reuse

3 11530022 Spring Washer Reuse

3 11200298 Hexagon Head Screw Reuse

4 42060034 Lifting Bracket Reuse

5 11560020 Screwed Plug Reuse

6 11130014 Sealing Ring Reuse

9 31080040 Cable Cap Reuse

10 31080546 Cable Cap Reuse

11 31080020 Cable Cap Reuse

12 11210235 Cylinder Screw Reuse

14 32980026 SEAL BUSHING, M8/9 150+185 2 Submerged in water. Replace per Contract

15 32980011 FITTING, CONTROL CABLE CAP, M5-9 Submerged in water. Replace per Contract

16 32980009 BUSHING, SEAL, GRD LEAD, E6 Submerged in water. Replace per Contract

17 43070691 CABLE SEAL, AWG4/0 Submerged in water. Replace per Contract

18 43070456 SEAL M5-M9 W/7X1.5 Submerged in water. Replace per Contract

20 11120022 O-RING, 62X4, NBR70 Submerged in water. Replace per Contract

21 11120318 O-Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

22 11120318 O-Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

23 12940263 Cable Entry Reuse

24 12940087 Cable Entry Reuse

25 12940025 CABLE ENTRY 5482-19-20-0 PG 29 Submerged in water. Replace per Contract New part numbers listed below

26 12100248 Electric Cable Submerged in water. Replace per Contract New part numbers listed below

26 12100248 Electric Cable Submerged in water. Replace per Contract New part numbers listed below

26 12100248 Electric Cable Submerged in water. Replace per Contract New part numbers listed below

26 12100248 Electric Cable Submerged in water. Replace per Contract New part numbers listed below

26 12100248 Electric Cable Submerged in water. Replace per Contract New part numbers listed below

26 12100248 Electric Cable Submerged in water. Replace per Contract New part numbers listed below

27 12100223 Electric Cable Submerged in water. Replace per Contract New part numbers listed below

28 12100249 Electric Cable Submerged in water. Replace per Contract New part numbers listed below

29 12180120 Cable Socket Submerged in water. Replace at no cost to customer.

30 12180087 Cable Socket Submerged in water. Replace at no cost to customer.

31 12180065 Cable Socket Submerged in water. Replace at no cost to customer.

32 31280046 Top Bearing Ring Reuse

33 11120319 O-Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

34 11550059 Grooved Pin Reuse

35 42130453 Seal-Probe Submerged in water. Replace per Contract

35 43045000 SEAL, DI-PROBE, 26MM H Submerged in water. Replace per Contract

35 11080027 CIRCLIP, 7X0.9, DIN6799, VZ. Submerged in water. Replace per Contract

35 42150102 STRAP, DI-PROBE Submerged in water. Replace per Contract

35 11210024 SCREW, HEX, M8X16, DIN 933 1.4401 Submerged in water. Replace per Contract

35 12180038 Cable Socket Submerged in water. Replace per Contract

35 11210525 Cylinder Screw Submerged in water. Replace per Contract

39 33030123 PROTECTION SLEEVE Submerged in water. Replace per Contract

40 33030128 PROTECTION SLEEVE M6-9 Submerged in water. Replace per Contract

41 33030126 SLEEVE, PROTECTION, M6-9, 1.5 SQ Submerged in water. Replace per Contract

42 11080010 Circlip Reuse

43 31150127 Top Bearing Cover Reuse

44 11200077 Hexagon Head Screw Reuse

46 11120163 O-RING, 150X4, DIN3771, NBR70 Submerged in water. Replace per Contract

47 11010093 Cylindric Roller Bearing Submerged in water. Replace per Contract Part of Bearing Kit 61700719

48 12120029 KLIXON, BRG, 140DEG C Submerged in water. Replace per Contract

49 11090063 Lip Seal Submerged in water. Replace per Contract Part of Bearing Kit 61700719

50 34310006 TERMINAL BOARD, M8/9 M20-MS Submerged in water. Replace per Contract

50 11400017 NUT,HEX,M20 ISO 4032-MA Submerged in water. Replace per Contract

50 B3LNL20034 LOCK WASHER Submerged in water. Replace per Contract

50 11470091 WASHER,21.0 DIN 125 A MS Submerged in water. Replace per Contract

50 11210084 SCREW, CYLIN, M12X45DIN128.8VZ Submerged in water. Replace per Contract

51 12200023 TERMINAL BLOCK, 9POLE, M6 Submerged in water. Replace per Contract

51 11470031 WASHER, 6.4, DIN125 Submerged in water. Replace per Contract

51 11400031 NUT, M6, DIN934 Submerged in water. Replace per Contract

51 11400052 NUT,HEX,M6, DIN985,8VZ Submerged in water. Replace per Contract

51 11210025 SCREW, ALLEN, M6X16, CAD, DIN 912 Submerged in water. Replace per Contract

52 11210080 Cylinder Screw Reuse

53 11470034 Washer Reuse

54 12170027 Terminal Reuse

55 65521450 Winding Assembly Reuse

65 65581136 Shaft Assembly Reuse

66 11630076 Key Reuse

67 31030147 Intermediate Flange Reuse

68 11350123 Stud Reuse

70 11400088 Hexagon Nut Reuse

71 11350124 Stud Reuse

73 11400087 Hexagon Nut Reuse

74 11560020 Screwed Plug Reuse

75 11130014 Sealing Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

76 11560020 Screwed Plug Reuse

77 11130014 Sealing Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

78 12130036 Terminal Strip Reuse

79 11260007 Flat Head Screw Reuse

80 11120202 O-Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

81 12160011 FERRULE 1.00MM/ DT Submerged in water. Replace per Contract

81 42130453 SEAL PROBE Submerged in water. Replace per Contract

81 43045000 Sealing Ring Submerged in water. Replace per Contract

81 11080027 Circlip Submerged in water. Replace per Contract

81 42150102 Clamp Submerged in water. Replace per Contract

81 11210024 Cylinder Screw Submerged in water. Replace per Contract

81 12180038 CABLE SOCKET 0.3-1.5 M4 Submerged in water. Replace per Contract

81 11210525 CYLINDER SCREWM4X12DIN912 Submerged in water. Replace per Contract

85 31760526 Bearing Flange Reuse

86 113500113 Stud Reuse

88 11400009 Hexagon Nut Reuse

89 11120126 O-Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

90 31150130 Bearing Cover Reuse

91 11350093 Stud Reuse

93 11400007 Hexagon Nut Reuse

94 11120116 O-Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

95 11020045 Angular Ball Bearing Submerged in water. Replace per Contract Part of Bearing Kit 61700719

96 11020044 Angular Ball Bearing Submerged in water. Replace per Contract Part of Bearing Kit 61700719

97 42350339 Spacer Ring Reuse

98 42350338 Spacer Ring Reuse

99 12120015 KLIXON, 120 DEG C Submerged in water. Replace per Contract

100 11020037 Shaft Nut Reuse

101 11640022 LOCK WASHER Reuse

106 11100062 Mechanical Seal Submerged in water. Replace per Contract Part of Upper Mechanical Seal Kit 61700313

107 11070041 Circlip Reuse

108 11030021 Sliding Oil Submerged in water. Replace per Contract

109 12160011 Ferrule Submerged in water. Replace per Contract

109 42130456 SEAL PROBE Submerged in water. Replace per Contract

109 43045000 Sealing Ring Submerged in water. Replace per Contract

109 11080027 Circlip Submerged in water. Replace per Contract

109 12180038 Cable Socket Submerged in water. Replace per Contract

109 11210525 Cylinder Screw Submerged in water. Replace per Contract

112 42240076 Name Plate Reuse

113 11550024 Grooved Pin Reuse

151 31040140 Oil Chamber Reuse

152 11210247 Cylinder Screw Reuse

154 11560020 Screwed Plug Reuse

155 11130014 Sealing Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

156 11120264 O-Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

157 11110053 Mechanical Seal Submerged in water. Replace per Contract Part of Lower Mechanical Seal Kit 61700720

158 42010121 Washer Reuse

159 11070047 Circlip Reuse

168 13810011 Screwed Connection Reuse

169 15060103 Shrinking Hose Reuse

170 11121107 O-Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

171 32010125 Washer Reuse

172 11070048 Circlip Reuse

173 11210187 Cylinder Screw Reuse

174 11490028 Lockwasher Reuse

175 11210186 Cylinder Screw Reuse

177 11130070 USIT -Ring Reuse

178 11121105 O-Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

179 11550056 Grooved Pin Reuse

180 11210235 Cylinder Screw Reuse

184 11120329 O-Ring Reuse

241 41240008 Diffuser Reuse

242 42700535 Bellmouth Reuse

243 41340165 Wear Ring Reuse

245 61070950 Propeller Reuse

246 41590147 Cap Reuse

247 42160016 Grooved Nut Reuse

249 11350142 Stud Reuse

251 11400015 Hexagon Nut Reuse

255 12180087 Cable Socket Reuse

331 32320524 Mounting Washer Reuse

380 31020097 Top Cover Reuse

381 11120143 O-Ring Submerged in water. Replace per Contract Part of O-Ring Kit 61701221

382 11210235 Cylinder Screw Reuse

383 34020541 Mounting Plate Reuse

384 11210080 Cylinder Screw Reuse

385 11470015 Washer Reuse

435 42230107 Clamp Reuse

436 11200204 Hexagon Head Screw Reuse

437 11490026 Lockwasher Reuse

12100172 CABLE, H07RN-F 4G120-VERIFY Submerged in water. Replace per Contract

43070028 SEAL, CABLE, SEC NOZ 4X120 H07 Submerged in water. Replace per Contract

12940155 CABLE ENTRY 74340.61-0 M80X2 Submerged in water. Replace per Contract

12100040 CABLE, H07RN, 8X1.5,D18.5 Submerged in water. Replace per Contract

43070093 CABLE SEAL 11X1.5 Submerged in water. Replace per Contract

61700719 BEARING KIT M9-VUP/AFP4X26 Submerged in water. Replace per Contract

61700313 MECH SEAL KIT, UPPER AFP6004X Submerged in water. Replace per Contract

61700720 MECH SEAL KIT, LOWER AFP6004X Submerged in water. Replace per Contract

61701221 KIT, ORGIN, VUPX1001 M2200/12 Submerged in water. Replace per Contract

ISO 32 OIL GS232 SEAL OIL - GALLON Submerged in water. Replace per Contract